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Industrial Press Operations Hydraulic and Mechanical Risk Assessment

This risk assessment covers hydraulic and mechanical industrial press operations, including setup, production, adjustments, jam clearing, maintenance and emergency shutdown.

Activities covered include

  • Plan press work and set up the work area
  • Clear jams, misfeeds and abnormal conditions
  • Respond to emergencies and shut down the press

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Industrial Press Operations Hydraulic and Mechanical Risk Assessment
  • 100% Compliant with Australian WHS Acts & Regulations
  • Fully Editable MS Word & PDF Formats Included
  • Pre-filled Content - Ready to Deploy Immediately
  • Customisable - Easily Add Your Logo & Site Details
  • Includes 2 Years of Free Compliance Updates

Product Overview

This risk assessment covers hydraulic and mechanical industrial press operations, including setup, production, adjustments, jam clearing, maintenance and emergency shutdown. It supports planning work and managing hazards from moving parts, stored energy, tooling, materials, noise and ejected items.

Activities & Risks Covered

This assessment addresses activities and risks including:

  • Plan press work and set up the work area
  • Check press condition, guarding and safety devices
  • Install tooling, change dies and complete setup adjustments
  • Carry out normal production pressing operations
  • Feed, unload and handle materials during press work
  • Clear jams, misfeeds and abnormal conditions
  • Undertake press maintenance, fault finding and cleaning
  • Monitor hydraulic and mechanical system condition
  • Manage noise, flying particles and other operator exposures
  • Respond to emergencies and shut down the press

Who is this for?

For contractors, workers, supervisors and businesses carrying out industrial press operations.

Activities & Hazards Covered

Activity Potential Hazards
Pre-start planning and work area setup
  • Unplanned access to the press danger zone by workers, contractors or visitors
  • Incorrect job setup, tool selection or material specification causing ejection, jam or overload
  • Poor housekeeping creating slip, trip and restricted access risks around the press
  • Workers using the press without current instruction, supervision or understanding of limits and emergency controls
Press condition, guarding and safety devices
  • Crush, entanglement or amputation from access to ram, dies, flywheel, clutch, gears or other moving parts
  • Injury from missing, loose, damaged or defeated guards and interlocks
  • Failure of light curtains, presence-sensing devices, two-hand controls or emergency stops
  • Contact with ejected parts or work pieces
Tooling installation, die changes and setup adjustment
  • Crush injuries during die change, ram movement or stored energy release
  • Strains and sprains from manual handling of dies, guards, clamps and fixtures
  • Pinch points when aligning tooling, bolting up or adjusting stops
  • Incorrectly secured tooling causing die movement, breakage or ejection on start-up
Normal production pressing operations
  • Hands or body entering the point of operation
  • Being struck by ejected stock, slug, off-cut or failed tooling
  • Unexpected press cycle due to faulty controls, double feed or inadvertent activation
  • Operator distraction, fatigue or poor communication leading to unsafe positioning
Manual feeding, unloading and material handling
  • Hazardous manual tasks from repetitive feeding, reaching, twisting and handling sheet, blanks or formed parts
  • Cuts from sharp edges, burrs and scrap
  • Crush or pinch injuries when positioning work pieces or removing finished parts
  • Dropped loads or awkward postures when handling heavy or unstable stock
Clearing jams, misfeeds and abnormal conditions
  • Crush or amputation if a jam is cleared while the press remains energised or capable of movement
  • Stored hydraulic, pneumatic, electrical, mechanical or gravitational energy releasing unexpectedly
  • Contact with sharp scrap, damaged tooling or trapped material
  • Unplanned restart while hands or tools are in the danger area
Maintenance, fault finding and cleaning
  • Unexpected movement during maintenance, lubrication, inspection or cleaning
  • Exposure to electrical, hydraulic, pneumatic or stored mechanical energy
  • Slips from oils, grease and cleaning residues
  • Injury from contact with hot components, sharp edges or damaged parts
Hydraulic and mechanical system integrity
  • Hydraulic hose or fitting failure causing fluid injection, leaks or sudden loss of control
  • Mechanical failure of clutch, brake, linkage, fasteners or frame creating uncontrolled movement
  • Noise, vibration and heat from deteriorating plant condition
  • Fire risk from leaking oil contacting hot surfaces or ignition sources
Noise, flying particles and other operator exposures
  • Hearing damage from repeated impact noise
  • Eye and face injuries from metal fragments, slugs or broken tooling
  • Skin contact with oils, coolants or contaminated surfaces
  • Respiratory exposure where pressing work creates dust, scale or fine particulate during associated handling or clean-up
Emergency response and shutdown
  • Delay in stopping the press during entrapment, injury, fire or plant failure
  • Panic or poor coordination during an emergency
  • Unsafe rescue attempts exposing others to crush or entanglement hazards
  • Failure to preserve the area after a serious incident

Need to tailor this risk assessment?

Use the BlueSafe Portal to add site-specific activities, hazards, controls, responsibilities and review details before the assessment is put into use.

Acceptance Guaranteed: If your client or principal requests changes during document review, BlueSafe will help revise the document at no extra cost and support resubmission until it is accepted.

Legislation & References

The template records model guidance used to inform the documented controls. Applicable WHS/OHS laws and adopted Codes vary by state or territory, so confirm the current local requirements when tailoring the assessment:

  • Model guidance: Model Code of Practice: Managing risks of plant in the workplace — 4.1 Guarding plant; p. 39.
  • Model guidance: Model Code of Practice: Hazardous manual tasks — 4.1 The hierarchy of control measures; p. 31.
  • Model guidance: Model Code of Practice: First aid in the workplace — 3. First aid equipment, facilities and training; p. 12.
  • Model guidance: Model Code of Practice: Managing the work environment and facilities — 2. The work environment; p. 13.
  • Model guidance: Model Code of Practice: Managing the risk of fatigue at work — Provide sufficient breaks while at work; p. 30.
  • Model guidance: Model Code of Practice: Managing noise and preventing hearing loss at work — 5. Controlling the risks; p. 29.
  • Model guidance: Model Code of Practice: How to manage work health and safety risks — 5. Step 4 — How to review controls; p. 27.
Standard Risk Assessment Features (Click to Expand)
  • Activity-specific hazard identification and control measures
  • Initial and residual risk ratings
  • Assigned responsible persons for each activity
  • Risk matrix and assessment classification
  • Review, monitoring and sign-off fields
  • Site-specific customisation before use

Suitable for Industries

Manufacturing and ProductionMetal Fabrication and WeldingMining and Resources

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